Electrical energy transfer system for a wire mesh heater

Abstract

The present teachings disclose a wire mesh heater including: a wire mesh element having a surface area comprising a non-contact area and a contact area; a primary conductor having a hollow and a contact surface; and a secondary conductor including a configured to expand outwards. The contact area contacts the contact surface to provide an electrical connection between the wire mesh element and the primary conductor, and the primary conductor is disposed about the secondary conductor and secured to the secondary conductor when expanded.

I claim: 
     
       1. A wire mesh heater comprising:
 a wire mesh element having a surface area comprising a non-contact area and a contact area; 
 a primary conductor which is hollow and has a contact surface; and 
 a secondary conductor configured to expand outwards, 
 wherein the contact area contacts the contact surface to provide an electrical connection between the wire mesh element and the primary conductor, and the primary conductor is disposed about the secondary conductor and secured to the secondary conductor when the secondary conductor is expanded outwards. 
 
     
     
       2. The wire mesh heater of  claim 1 , wherein the contact area of the wire mesh element is welded to the primary conductor. 
     
     
       3. The wire mesh heater of  claim 1 , wherein the secondary conductor includes a void with a tightening rod disposed in the void, and the secondary conductor expands outwards by tightening the tightening rod with a nut. 
     
     
       4. The wire mesh heater of  claim 1 , wherein the secondary conductor includes a void with a tightening rod disposed in the void, a plurality of blocks having complementary bias surfaces, and the secondary conductor expands outwards by tightening the tightening rod with a nut. 
     
     
       5. The wire mesh heater of  claim 1 , wherein the secondary conductor includes a quill stem including a tightening rod and nut disposed on the tightening rod, and the secondary conductor expands outwards by tightening the tightening rod with the nut. 
     
     
       6. The wire mesh heater of  claim 1 , further comprising:
 a heating cavity comprising a first surface defined by the non-contact area of the wire mesh element; and 
 a heat shield disposed in the heating cavity, 
 wherein the heat shield is disposed adjacent to the primary conductor to reflect a majority of heat radiation generated by the non-contact area away from the primary conductor. 
 
     
     
       7. The wire mesh heater of  claim 1 , further comprising:
 a Direct Current (DC) power supply; and 
 a braided electrical cable to electrically connect the DC power supply with the secondary conductor. 
 
     
     
       8. The wire mesh heater of  claim 1 , wherein the secondary conductor is partially segmented. 
     
     
       9. The wire mesh heater of  claim 1 , further comprising:
 a chassis to secure the secondary conductor. 
 
     
     
       10. The wire mesh heater of  claim 9 , further comprising:
 a Direct Current (DC) power supply; and 
 a braided electrical cable to electrically connect the DC power supply with the secondary conductor to electrically connect the DC power supply with the primary conductor. 
 
     
     
       11. The wire mesh heater of  claim 9 , further comprising:
 a heating cavity comprising a first surface defined by the non-contact area of the wire mesh element; and 
 a heat shield disposed in the heating cavity, 
 wherein the heat shield is disposed adjacent to the primary conductor to reflect a majority of heat radiation generated by the non-contact area away from the primary conductor. 
 
     
     
       12. The wire mesh heater of  claim 9 , further comprising tension springs disposed between the primary conductor and the secondary conductor. 
     
     
       13. The wire mesh heater of  claim 9 , further comprising:
 a heating cavity comprising a first surface defined by the non-contact area of the wire mesh element; and 
 a first heat shield disposed in the heating cavity disposed adjacent to the primary conductor to reflect a majority of heat radiation generated by the non-contact area away from the primary conductor. 
 
     
     
       14. The wire mesh heater of  claim 1 , wherein the primary conductor is partially segmented. 
     
     
       15. The wire mesh heater of  claim 1 , wherein the primary conductor comprises a sleeve coated with a heat-resistant alloy. 
     
     
       16. The wire mesh heater of  claim 1 , wherein the non-contact area of the wire mesh element comprises an edge area that is angled with respect to a non-edge area of the non-contact area of the wire mesh element. 
     
     
       17. The wire mesh heater of  claim 1 , wherein the primary conductor comprises a non-contact surface covered by an electrical insulator. 
     
     
       18. The wire mesh heater of  claim 17 , wherein the electrical insulator has a thickness of at least 0.03 inches and the electrical insulator comprises an insulative paint or a ceramic coating. 
     
     
       19. The wire mesh heater of  claim 1 , wherein the secondary conductor comprises a metal rod coated with a heat-resistant alloy. 
     
     
       20. The wire mesh heater of  claim 1 , wherein the contact area is disposed along at least 50% of a wire mesh element length.